Illumination apparatus for a barcode reader

ABSTRACT

Illumination systems for illuminating objects to be read or imaged by optical readers, such barcode scanners and direct part marking (DPM) barcode readers, are provided. One implementation includes an illumination apparatus including a light source and a freeform lens having a cavity configured to at least partially surround the light source. The freeform lens is configured to provide both dark field illumination and bright field illumination to an object to be imaged.

FIELD OF THE INVENTION

The present invention relates to barcode readers and more particularly relates to illumination systems used with barcode readers.

BACKGROUND

Barcodes may be applied to various products in different ways. Conventional barcodes may be attached to products using pre-printed barcode labels or may be printed directly onto the product itself. Other ways of applying barcodes to products may include a technique known as direct part marking (DPM), which is a process of permanently marking objects with barcodes or other information. The DPM process may include creating one-dimensional symbols (e.g., Code 39 codes, Code 128 codes, etc.) or two-dimensional symbols (e.g., Data Matrix codes, quick response (QR) codes, etc.). The DPM process may include marking the objects using various marking techniques, such as by engraving, laser marking, embossing, abrasive blasting, molding, electrochemical etching, or other techniques.

Since the various types of DPM barcodes may be applied using different techniques and may be applied to different surfaces, typical DPM barcode readers require multiple illumination systems to read the DPM barcodes. The illumination systems usually contain at least two assemblies, a first assembly including a dark field illumination system that provides low angle incident lighting on the barcode substrate. Dark field illumination is usually needed for reading barcodes that are embossed on a highly reflective substrate. A second assembly of the illumination systems may include a bright field illumination system, which provides high angle incident lighting on the substrate. Bright field illumination is usually needed for reading barcodes engraved on a diffused or non-polished metal surface. An optional third assembly may include light-diffusing illumination components, which may be used to assist in reading a barcode engraved on a curved surface.

The multiple illumination system assemblies for assisting the DPM barcode readers can therefore be complex to assemble, bulky, and expensive. Also, these illumination systems can consume a high amount of power, particularly because of the high number of light emitting diodes (LEDs) that are needed for proper illumination. Therefore, a need exists for a simpler, less expensive, and more energy efficient illumination system that may be used for DPM barcode readers.

SUMMARY

Accordingly, in one aspect, the present invention embraces optical reading devices, illumination systems for optical reading devices, and more specifically freeform lens used in illumination systems. In an exemplary embodiment, an optical reading device includes one or more illumination devices and an imager configured to scan an object. Each of the illumination devices is configured to provide dark field illumination and bright field illumination to the object.

In another exemplary embodiment, an illumination apparatus comprises a light source and a freeform lens having a cavity configured to at least partially surround the light source. The freeform lens is configured to provide both dark field illumination and bright field illumination to an object to be imaged.

In yet another exemplary embodiment, a freeform lens is provided. The freeform lens includes a first section configured to direct light rays from a light source to provide dark field illumination. The freeform lens further includes a second section configured to direct light rays from the light source to provide bright field illumination.

The foregoing illustrative summary, as well as other exemplary objectives and/or advantages of the invention, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically depicts a freeform lens for providing dark field illumination and bright field illumination, according to an embodiment of the present invention.

FIG. 2 schematically depicts a first side view of the freeform lens of FIG. 1, according to an embodiment of the present invention.

FIG. 3 schematically depicts a second side view of the freeform lens of FIG. 1, according to an embodiment of the present invention.

FIG. 4 schematically depicts a front view of the freeform lens of FIG. 1, according to an embodiment of the present invention.

FIG. 5 schematically depicts a cross-sectional front view of the freeform lens of FIG. 1, according to an embodiment of the present invention.

FIG. 6 schematically depicts a top view of the freeform lens of FIG. 1, according to an embodiment of the present invention.

FIG. 7 schematically depicts a representation of light rays passing through the freeform lens of FIG. 1, according to an embodiment of the present invention.

FIG. 8 schematically depicts an optical reading system, according to an embodiment of the present invention.

FIG. 9 schematically depicts a view of the optical reading system of FIG. 8, according to an embodiment of the present invention.

DETAILED DESCRIPTION

The present invention embraces barcode readers or barcode scanners for reading barcodes attached to or applied to objects. More particularly, the present invention may be directed to direct part marking (DPM) barcode readers for reading barcodes that have been permanently marked on an object. DPM barcodes and other information may be applied to objects using a variety of techniques, such as by engraving, laser marking, embossing, abrasive blasting, molding, electrochemical etching, and/or other techniques. In addition, the marking processes may be applied to various types of surfaces of the objects.

Because a DPM barcode may have many different physical characteristics based on the various methods of applying the barcode and the various surfaces on which the barcode may be applied, DPM barcode readers may require illumination from many different angles. Otherwise, the barcodes may not be read properly. The illumination systems described in the present disclosure are able to provide dark field illumination for certain barcodes (e.g., barcodes embossed on a highly reflective surface) that may need low angle incident lighting on the substrate in order to be read properly. Furthermore, the illumination systems described herein are able to provide bright field illumination for other types of barcodes (e.g., barcodes engraved on a diffused or non-polished metal surface) that may need high angle incident lighting on the substrate in order to be read properly.

The illumination systems for DPM barcode readers, as described herein, are able to provide dark field illumination and bright field illumination using a simple light source and a lens having a freeform design. The illumination systems can therefore provide adequate illumination for various optical reading processes regardless of the manner in which the barcode has been applied to an object and regardless of the physical characteristics of the object. The illumination systems of the present invention can be manufactured at a fraction of the cost of conventional illumination systems. Furthermore, the present disclosure provides illumination systems that may be less bulky, less complex, and more energy efficient than conventional systems.

FIG. 1 illustrates an orthogonal view of an embodiment of a freeform lens 10 for providing dark field illumination and bright field illumination. The freeform lens 10 in general contains two main sections, a first section 12 shown primarily in the lower right portion of FIG. 1 and a second section 14 shown primarily in the upper left portion of the figure.

FIG. 2 illustrates a first side view (from the left-hand side) of the freeform lens 10 of FIG. 1 having the second section 14 in the foreground. FIG. 3 illustrates a second side view (from the right-hand side) of the freeform lens 10 of FIG. 1 from the opposite side having the first section 12 in the foreground. FIG. 4 illustrates a front view or side view of the freeform lens 10 of FIG. 1 having the first section 12 on the right and the section 14 on the left. FIG. 5 illustrates a cross-sectional side view of the freeform lens 10 of FIG. 1. Also, FIG. 6 illustrates a top view of the freeform lens 10. Therefore, FIGS. 1-6 may be considered in combination showing the freeform lens 10 from many different angles.

The first section 12 of the freeform lens 10 is configured to direct light rays from a light source to provide dark field illumination. For example, dark field illumination refers to an illumination pattern directed at a low incident angle with respect to an object bearing a barcode. In particular, light rays in dark field illumination may be considered to travel in a substantially horizontal direction when viewed with respect to FIGS. 2-5 and to travel in a substantially outwardly radiating direction when viewed with respect to FIG. 6.

The second section 14 is configured to direct light rays from the light source to provide bright field illumination. For example, bright field illumination refers to an illumination pattern directed at a high incident angle with respect to the object. In particular, light rays in bright field illumination may be considered to travel in a substantially upward direction when viewed with respect to FIGS. 2-5.

The first section 12 is symmetrical about an optical axis 16 for about 180 degrees around the optical axis 16. Likewise, the second section 14 is also symmetrical about the optical axis 16 for about 180 degrees around the axis. In some embodiments, the first section 12 and second section 14 may be more or less than 180 degrees, depending on the desired angular range of dark field illumination. For example, according to an alternative embodiment, the first section 12 may extend more than 180 degrees (e.g., 270 degrees) around the optical axis 16 and the second section 14 may extend less than 180 degrees (e.g., 90 degrees). In this way, the dark field illumination may be spread out horizontal for more than 180 degrees in various directions.

Bottom portions of the first and second sections 12, 14 define a cavity 18 (FIG. 5) configured to at least partially surround a light source. The bottom portions of the first and second sections 12, 14 include a first outwardly-curved refractive surface 20 and a first conical refractive surface 22. The first outwardly-curved refractive surface 20 may be spherical or aspherical. A light source placed in or near the cavity 18 may be configured to transmit light that enters the interior of both sections 12, 14 of the freeform lens 10 via the first outwardly-curved refractive surface 20 and the first conical refractive surface 22. The first conical refractive surface 22 may be curved slightly inwardly or outwardly (i.e., concave or convex) depending on various embodiments.

The first section 12 of the freeform lens 10 also includes an ellipsoidal refractive surface 24, a concave conical reflective surface 26, and a second conical refractive surface 28. It should be noted that both surfaces 26 and 28 have a substantially conical shape, but may be curved slightly outward with respect to the interior of the first section 12 of the freeform lens 10 in some embodiments. The concave conical reflective surface 26 may be concave or curved inwardly toward a center portion of a respective imaginary cone and the second conical refractive surface 28 may be convex or curved outwardly away from a center portion of another respective imaginary cone. The slight concave and convex curvature of the surfaces 26 and 28 may assist in optimizing the dark field illumination.

In addition to the surfaces 20 and 22, the second section 14 of the freeform lens 10 includes an outwardly-curved reflective surface 30, a planar refractive surface 32, and a second outwardly-curved refractive surface 34. In some embodiments, the planar refractive surface 32 may be tilted slightly with respect to the optical axis 16. The outwardly-curved surfaces 30 and 34 may be spherical or aspherical.

A portion of the light rays transmitted from a light source positioned in the cavity 18 are refracted by the first outwardly-curved refractive surface 20 and traverse the interior of both the first and second sections 12, 14 of the freeform lens 10. Also, another portion of the light rays from the light source are refracted by the first conical refractive surface 22 and traverse the interior of both the first and second sections 12, 14 of the freeform lens 10. Thus, light rays from the light source enter the freeform lens 10 through the first outwardly-curved refractive surface 20 and the first conical refractive surface 22.

The concave conical reflective surface 26 of the first section 12 is configured to internally reflect a portion of the light rays passing through the first outwardly-curved refractive surface 20. The second conical refractive surface 28 is configured to refract the light rays internally reflected by the concave conical reflective surface 26 to provide dark field illumination. Also, the ellipsoidal refractive surface 24 is configured to refract a portion of the light beams passing through the first conical refractive surface 22 to provide additional dark field illumination.

The freeform lens 10 is configured such that the outwardly-curved reflective surface 30 of the second section 14 is configured to internally reflect a portion of the light rays passing through the first conical refractive surface 22. The planar refractive surface 32 is configured to refract the light rays internally reflected by the outwardly-curved reflective surface 30 to provide bright field illumination. Also, the second outwardly-curved refractive surface 34 is configured to refract a portion of the light rays refracted by the first outwardly-curved refractive surface 20 to provide additional bright field illumination.

FIG. 7 illustrates a cross-sectional view of the freeform lens 10 of FIG. 1 and a representation of a sample of light rays passing through the freeform lens 10. A light source 40, such as an LED, is positioned in or near the cavity 18 for transmitting light rays onto the first outwardly-curved refractive surface 20 and the first conical refractive surface 22. The combination of the freeform lens 10 and the light source 40 can be referred to as an illumination device 44 for providing both dark field illumination and bright field illumination.

A first portion of the light rays transmitted by the light source 40 are refracted by the first conical refractive surface 22 and enter the first section 12 of the freeform lens 10. This first portion of light rays traverses the interior of the first section 12 of the freeform lens 10 and is refracted by the ellipsoidal refractive surface 24 to provide dark field illumination.

A second portion of the light rays transmitted by the light source 40 are refracted by the first outwardly-curved refractive surface 20 and enter the first section 12 of the freeform lens 10. This second portion of light rays traverses the interior of the first section 12 of the freeform lens 10 and is internally reflected by the concave conical reflective surface 26. These light rays then encounter the second conical refractive surface 28, which refracts the light rays to provide additional dark field illumination.

A third portion of the light rays transmitted by the light source 40 are refracted by the first outwardly-curved refractive surface 20 and enter the second section 14 of the freeform lens 10. This portion of the light rays traverses the interior of the second section 14 of the freeform lens 10 and is refracted by the outwardly-curved refractive surface 34 to provide bright field illumination.

In addition, a fourth portion of the light rays transmitted by the light source 40 are refracted by the first conical refractive surface 22 and enter the second section 14 of the freeform lens 10. This portion of the light rays is then internally reflected by the outwardly-curved reflective surface 30 and directed toward the planar refractive surface 32. The planar refractive surface 32 refracts the light rays to provide additional bright field illumination.

FIG. 8 illustrates an embodiment of an optical reading device 42. The optical reading device 42 includes a plurality of illumination devices 44. Each illumination device 44 may include any combination of light sources and lenses. According to some embodiments, the illumination device 44 may include one or more LEDs and a freeform lens. In some embodiments, the freeform lens of each of the illumination devices 44 may be the freeform lens 10 described with respect to FIGS. 1-6.

The optical reading device 42 further includes an imager 46 configured to scan an object that has been illuminated by the one or more illuminations devices 44. Each of the illumination devices 44 is configured to provide dark field illumination and bright field illumination to the object. In particular, the illumination devices 44 may be oriented such that the dark field illumination is directed in the vicinity of the field of view of the imager 46. With respect to FIG. 8, the illumination pattern of the dark field illumination from the different illumination devices 44 may be directed inwardly toward the imager 46.

The imager 46 of the optical reading device 42 may be a barcode scanner and the object being read may be a barcode. The barcode may be a one-dimensional barcode (e.g., a Code 39 code, a Code 128 code, etc.) a two-dimensional code (e.g., a data matrix code, a quick response (QR) code, etc.), and/or other types of code. In some embodiments, the barcode may be a direct part marking (DPM) code permanently applied to the object.

As illustrated in FIG. 9, the illumination devices 44 shown in FIG. 8 may be positioned around the imager 46. The illumination devices 44 may each comprise a light source 40, such as an LED, and a freeform lens, such as the freeform lens 10 described herein. According to some embodiments, the optical reading device 42 may be configured with any freeform lens that provides both dark field illumination and bright field illumination.

With the positioning of the illumination devices 44, the object within the field of view (FOV) of the imager 46 may be illuminated from many different angles. The freeform lens shown in FIG. 9, which may be configured as the freeform lens 10 described with respect to FIGS. 1-6, may include a first part that is configured to provide dark field illumination to the object and a second part that is configured to provide bright field illumination to the object.

Each of the plurality of illumination devices 44 may be oriented such the first part of the illumination device 44, which provides dark field illumination, may be directed toward a center section of the optical reading device 42. In some embodiments, the different illumination devices 44 shown in FIGS. 8 and 9 may be activated separately. In this way, a user may be able to control the specific angular light distribution. In other embodiments, the freeform lenses of the illumination devices 44 shown in FIGS. 8 and 9 may be configured to provide different light distribution patterns. Therefore, with various illumination devices 44 activated, the angle of the light distribution can be adjusted as needed.

To supplement the present disclosure, this application incorporates entirely by reference the following commonly assigned patents, patent application publications, and patent applications:

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In the specification and/or figures, typical embodiments of the invention have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation. 

The invention claimed is:
 1. An optical reading device comprising: one or more illumination devices; and an imager configured to optically scan an object; wherein each of the illumination devices is configured to provide dark field illumination and bright field illumination to the object, each illumination device including a freeform lens comprised of a first radial section for providing the dark field illumination and an opposing second radial section for providing the bright field illumination.
 2. The optical reading device of claim 1, wherein each of the one or more illumination devices includes a light emitting diode (LED) and the freeform lens.
 3. The optical reading device of claim 1, wherein the imager is a barcode scanner, and wherein the object includes a barcode.
 4. The optical reading device of claim 3, wherein the barcode is one of a Code 39 code, a Code 128 code, a data matrix code, and a quick response (QR) code.
 5. The optical reading device of claim 3, wherein the barcode is a direct part marking (DPM) code permanently applied to the object.
 6. The optical reading device of claim 1, wherein the one or more illumination devices are configured as a plurality of illumination devices positioned around front edges of the imager.
 7. The optical reading device of claim 6, wherein the illumination devices are configured to be activated individually to form specific angular light distributions.
 8. An illumination apparatus comprising: a light source; and a freeform lens having a cavity configured to at least partially surround the light source, the freeform lens comprised of a first radial section for providing dark field illumination and an opposing second radial section for providing bright field illumination.
 9. The illumination apparatus of claim 8, wherein the first and second radial sections are each symmetrical about the optical axis of the freeform lens.
 10. The illumination apparatus of claim 9, wherein each of the first and second radial sections of the freeform lens includes an internally reflective surface.
 11. The illumination apparatus of claim 9, wherein each of the first and second radial sections of the freeform lens includes at least one refractive surface through which light beams are externally transmitted.
 12. A freeform lens comprising: a first section configured to direct light rays from a light source to provide dark field illumination; and a second section configured to direct light rays from the light source to provide bright field illumination, each of the first section and the second section defining a radial sector of the freeform lens.
 13. The freeform lens of claim 12, wherein the first section is symmetrical about an optical axis and the second section is symmetrical about the optical axis.
 14. The freeform lens of claim 12, wherein a first outwardly-curved refractive surface and a first conical refractive surface of bottom portions of the first and second sections define a cavity configured to at least partially surround the light source.
 15. The freeform lens of claim 14, wherein light rays from the light source enter the freeform lens through the first outwardly-curved refractive surface and the first conical refractive surface.
 16. The freeform lens of claim 15, wherein the first section comprises an ellipsoidal refractive surface, a concave conical reflective surface, and a second conical refractive surface.
 17. The freeform lens of claim 16, wherein: the concave conical reflective surface is configured to internally reflect a portion of the light rays passing through the first outwardly-curved refractive surface; the second conical refractive surface is configured to refract the light rays internally reflected by the concave conical reflective surface to provide dark field illumination; and the ellipsoidal refractive surface is configured to refract a portion of the light rays passing through the first conical refractive surface to further provide dark field illumination.
 18. The freeform lens of claim 15, wherein the second section comprises an outwardly-curved reflective surface, a planar refractive surface, and a second outwardly-curved refractive surface.
 19. The freeform lens of claim 18, wherein: the outwardly-curved reflective surface is configured to internally reflect a portion of the light rays passing through the first conical refractive surface; the planar refractive surface is configured to refract the light rays internally reflected by the outwardly-curved reflective surface to provide bright field illumination; and the second outwardly-curved refractive surface is configured to refract the light rays refracted by the first outwardly-curved refractive surface to further provide bright field illumination. 